Rearview mirror with integrated frame

ABSTRACT

An electrochromic mirror includes an integrated internal plate frame with an electrochromic mirror subassembly adhered to its flat front surface, electrical components supported on a rear with the frame acting as a heat sink and EMI/RFI shield, and a back cover supported on the plate frame. The subassembly is uniformly supported across the front surface of the plate frame for good mirror impact resistance. The mirror is supported by an angularly adjustable ball-and-socket connection. In one embodiment, the ball is formed integrally on the plate frame. The present mirror is surprisingly thin, with at least 50% of the depth dimensions being less than about 3.0 centimeters.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.10/405,526, entitled REARVIEW MIRROR WITH INTEGRATED FRAME, which wasfiled on Apr. 4, 2003, now U.S. Pat. No. ______.

BACKGROUND

The present invention concerns vehicle mirrors, and more particularlyrelates to rearview mirrors having an integrated frame.

Interior and exterior rearview mirrors of modern passenger vehicles havebecome heavier and heavier as more and more content and features areadded. For example, many modern vehicle mirrors include several of thefollowing options: electrochromic mirror subassemblies and circuitry toreduce glare, keyless entry sensing systems,microphone-speaker-antennae-phone communication systems, audio-controlsystems, compass and temperature devices and displays, lighting,switches for control of electrical circuits, and the like. Since mostvehicle mirrors are supported from one side (usually a back or topside),this added weight creates a pendulum effect that causes the mirrors toshake, vibrate, and resonate unacceptably. In order to reduce theshaking, vibration, and resonation, the rear support area on mostrearview mirrors is beefed up to increase rigidity and stability, and/orreinforcement ribs are added to the rear support area. However, anyincrease in wall thickness and/or increase in the number ofreinforcement ribs adds to part weight, adds to sinks and blemishes andother quality problems when molding the parts, and adds to partcomplexity. Further, the added ribs take up substantial space, making aprofile of the mirrors much larger. It is desirable to provide a mirrordesign where the number of reinforcement ribs and webs in a mirrorhousing are minimized or eliminated, and where the mirror housing isprimarily designed as a cosmetic covering rather than a structuralmember. It is noted that vehicle manufacturers have high visualstandards for the housings of interior rearview mirrors, since vehiclepassengers not only look at and touch the mirror housings often, butalso the mirrors are in a position where every blemish and defect iseasily seen.

Modern interior rearview mirrors are typically mounted from their hiddenbackside by an elongated mount, and are made to be angularly adjustableby a ball-and-socket connector that connects the mirror to the mount.This allows each vehicle driver to angularly adjust the mirror to anoptimal position and preference. The adjustable connector is madesufficiently rigid to hold the mirror in a selected angular position,even when receiving substantial vibrational stress. However, theadjustable connectors include multiple separate parts and pieces thatrequire assembly, and further take up space. It would be desirable toprovide a mount where the ball and socket connection was betterintegrated into one of the mirror components.

Still another concern is wire management. Modern vehicle mirrors canhave several wires connected to internal components within the mirrorhead. These wires need to be managed so that they do not becomeentangled or pinched during assembly or during angular adjustment.Further, mis-positioning of wires can cause substantial variation inelectromagnetic interference and radio frequency interference emittedfrom power-using electrical components on the mirror, which is ofincreasing concern to vehicle manufacturers. It is desirable to providea mirror having an integrated wire management system so that wires arewell managed and consistently located in the mirror, and so that thewires are integrally shielded along with the electrical devices thatthey are connected to.

Another concern is impact testing and vehicle safety. For example, atleast one vehicle manufacturer requires that the mirror glass not breakor result in separation of large glass pieces from the mirror,particularly where the glass pieces are more than 2.5 mm from a crackline, since loose broken glass can be injurious to a vehicle driver orpassenger. Hence, it is important that glass elements be supported in amanner that minimizes a tendency of the glass to be sharply bent andbroken upon impact, and that holds the glass elements in a mannerkeeping broken pieces from coming loose upon impact. This problem can becomplicated in an electrochromic (EC) mirror since an EC mirror has twoglass elements with an EC material therebetween.

In addition to the above problems, as mirrors have become increasinglycomplex and sophisticated, the number of parts and pieces necessary forassembly have increased. It is desirable to provide an improvement wherethe many parts and pieces can be assembled in a more open physicalarrangement, rather than having to be assembled into the cavity of aconcave mirror housing. It is also potentially preferable that themirror housing be designed more for “pure aesthetics”, such thatfunctional aspects are not as much of a concern.

Accordingly, an apparatus is desired having the aforementionedadvantages and solving and/or making improvements on the aforementioneddisadvantages.

SUMMARY OF THE PRESENT INVENTION

In one aspect of the present invention, a rearview mirror for vehiclesincludes an integrated plate frame, and an electrochromic mirrorsubassembly including at least one glass element and electrochromicmaterial, with the subassembly being supported by the plate frame. Acircuit configured to operate the electrochromic material is supportedon a rear of the plate frame, and a cover is supported by the plateframe that covers at least one of the rear and edges of the plate frame.

In another aspect of the present invention, a rearview mirror forvehicles includes an internal metal structural backing plate having aflat front surface, and an electrochromic mirror subassembly. The mirrorsubassembly includes front and rear glass elements and electrochromicmaterial therebetween, and is uniformly supported on the front surfaceof the metal backing plate for good impact resistance.

In another aspect of the present invention, a rearview mirror apparatusfor vehicles includes a mirror and a mount adapted to support the mirrorin a vehicle. The mirror includes an internal frame having a frontsurface, and an electrochromic mirror subassembly supported on the frontsurface. An angularly-adjustable connector adjustably supports themirror on the mount. The angularly-adjustable connector includes a ballsection and a socket-defining section, where the ball section is formedon one of the internal frame and the mount, and the socket-definingsection is formed on the other of the internal frame and the mount. Thesocket-defining section receives and supports the ball section forangular adjustment, but engages the ball section with sufficient forceand friction to hold the mirror in a selected angular position once themirror is released by a vehicle driver.

In another aspect of the present invention, a rearview mirror forvehicles includes an internal metal plate, and an electrochromic mirrorsubassembly supported in front of the plate. An electrical circuit issupported on the metal plate and is operably connected to theelectrochromic mirror subassembly. The metal plate has good heatconduction properties and acts as a heat sink for the circuit.

In another aspect of the present invention, a rearview mirror forvehicles includes an internal metal plate, and an electrochromic mirrorsubassembly supported in front of the plate. An electrical circuit issupported on the metal plate and is operably connected to theelectrochromic mirror subassembly. The electrical circuit includeselectrical devices that generate at least one of EMI emissions and RFIemissions, and the metal plate has an integrally-formed section shapedto at least partially cover and shield the electrical device to reduceEMI and RFI emissions.

In another aspect of the present invention, a rearview mirror forvehicles includes a mirror subassembly, and a frame supporting themirror subassembly. A cover is attached to the frame and covers a backand edges of the mirror subassembly. The mirror subassembly forms afront surface and the cover forms a rear surface of the mirror. Thefront and rear surfaces include areas defining a plurality of differentdepth dimensions, with at least 50% of the depth dimensions being lessthan about 3 centimeters.

In another aspect of the present invention, a rearview mirror forvehicles includes an internal plate. A back cover is supported by theplate and covers a rear of the plate. An electrochromic mirror elementis supported in front of the plate. At least one button is operablysupported by the plate, and an electrical circuit is supported by theplate and is operably connected to the button for controlling anelectrical feature of the vehicle.

In still another aspect of the present invention, a plate frame adaptedfor use in a rearview mirror for vehicles includes an internal plateframe including a smooth front surface adapted for supporting a rearviewmirror element. An integrally-formed protrusion extends rearwardly fromthe plate, the protrusion including a stem and a ball section on an endof the stem that is adapted to form a ball-and-socket connection forangularly and adjustably supporting the internal plate and mirrorelements attached to and supported by the internal plate.

In yet another aspect of the present invention, a plate frame adaptedfor use in a rearview mirror for vehicles includes an internal plateframe including a smooth front surface adapted for supporting a rearviewmirror element. An integrally-formed tubular section extends rearwardlyfrom the plate. Bearings form a socket in an end of the tubular section,the bearings being adapted to receive a ball section to form aball-and-socket connection for angularly and adjustably supporting theinternal plate frame and the rearview mirror element on a mirror mounthaving the ball section.

In another aspect of the present invention, a rearview mirror forvehicles includes an internal plate frame having a smooth front surface,a reflector layer on the front surface, an electrochromic materialcovering the reflector layer, and a glass element on the electrochromicmaterial that contains the electrochromic material on the reflectorlayer against the front surface.

These and other aspects, objects, and features of the present inventionwill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1-2 are front and top views of a mirror assembly embodying thepresent invention; FIG. 2A is similar to FIG. 2 but showing a thinnermirror assembly;

FIGS. 3-4 are cross-sectional views taken along the lines III-III andIV-IV in FIG. 1;

FIG. 5 is an enlargement of the circled area V in FIG. 3;

FIG. 6 is an exploded perspective view of the mirror in FIGS. 1-4;

FIG. 7 is a fragmentary cross-sectional view taken horizontally througha center of a first modified mirror assembly;

FIG. 8 is a cross-sectional view taken along the line VIII-VIII in FIG.7;

FIG. 9 is a fragmentary cross-sectional view similar to FIG. 7 but of asecond modified mirror assembly; and

FIG. 10 is a vertical cross-sectional view taken vertically through athird modified mirror assembly, including a button and switch operablypositioned on the plate frame;

FIGS. 11-13 are a fragmentary side view, a cross section, and afragmentary side view of alternative plate frames, where the plateframes include a tube, a ball and a socket to form a ball-and-socketconnection, FIG. 12 being a cross section taken along line XII-XII inFIG. 11;

FIGS. 14-15 are top and front views of a mirror embodying the presentinvention;

FIGS. 16-18 are cross sections, FIGS. 16 and 18 being taken along thelines XVI-XVI and XVIII-XVIII in FIG. 14, FIG. 17 being similar to FIG.16 but with the back cover and bezel removed for clarity;

FIG. 19 is an enlargement of the circled area XIX in FIG. 18;

FIGS. 20-21 are top and front views of a mirror embodying the presentinvention;

FIGS. 22-23 are cross sections taken along the lines XXII-XXII andXXIII-XXIII in FIG. 21;

FIGS. 24-25 are top and front views of another mirror embodying thepresent invention;

FIGS. 26-29 are cross sections, FIGS. 26 and 28 being taken along thelines XXVI-XXVI and XXVIII-XXVIII in FIG. 25, and FIGS. 27 and 29 beingsimilar to FIGS. 26 and 28 but with the back cover and bezel removed forclarity;

FIGS. 30-32 are front, cross section, and exploded perspective views ofadditional mirrors embodying aspects of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An apparatus 18 includes a mount 33 supporting an EC mirror 20 forangular adjustment (FIGS. 1-4) on the front windshield 19 of a vehicle.The electrochromic mirror 20 (FIG. 6) includes an internal plate frame21 (FIGS. 5-6) with an electrochromic (EC) mirror subassembly 22supported on a front surface 23 of the plate frame 21. Electricalcomponents 24 are supported by a circuit board 40 attached to a rearsurface 25 (or to the front surface 23) of the plate frame 21 with theplate frame 21 acting as a heat sink and as an EMI and/or RFI shield, asdiscussed below. A back cover 26 and bezel 27 are supported on aperimeter edge 28 of the plate frame 21 and cover the rear surface 25,the edge 28, and an outer edge of the EC mirror subassembly 22. In theillustrated embodiment of mirror 20, the EC mirror subassembly 22 isuniformly and continuously supported across the front surface 23 of theplate frame 21 (except at relatively small locations such asdisplay-receiving aperture 44) for good mirror impact resistance in avehicle crash. The mirror 20 is supported by an angularly adjustableball-and-socket connection 30 (FIG. 6) formed by a ball section 31 on aglass-attached mount 33, and a mating socket 32 in an attachmentcomponent 34 attached directly to the plate frame 21.

In the illustrated mirror 20 (FIG. 6), the socket 32 is formed by anattachment component 34 attached directly to the plate frame 21, and theball section 31 is formed on a mount 33. Due to the improvementsassociated with the plate frame 21, (and also plate frame 21A, 21B and21C described below) including its high strength and wide reach whilemaintaining a minimal thickness, the present mirror 20 (and mirrors20A-20C) is surprisingly thin, with at least 50% of the depth dimensionD1 (FIG. 3) being less than about 3 centimeters, and at least 50% of thedepth dimensions being less than 15% of the maximum width dimension W1.More preferably, at least about 50% of the depth dimensions are lessthan about 3.0 cm, and also are less than about 12% of a maximum widthdimension. Further, it is estimated that a weight of the mirror head canbe reduced by 10%-20% (see FIG. 5, the mirror head including theattachment component 34 but not including the ball section 31) and canbe reduced by as much as by 30%-40% (see FIGS. 7-10, the mirror headincluding a metal plate with an integrally formed ball section withwireway hole therethrough but not including the mount withsocket-forming bushings and coil spring). The present arrangement takesmaximum advantage of the high strength internal frame 21 and thelightweight cover 26 (as opposed to a much heavier plastic rear housingwith stiffening ribs around the pivotal-adjusting connection area) andfurther reduces a tendency of the mirror 20 to vibrate since there is alower pendulum effect. Specifically, the mirror 20 has a center ofgravity closer to the ball-and-socket connection, due to the thinnertotal mirror thickness, and has a reduced pendulum effect due to itslighter weight.

It is noted that the integrated plate frame 21 can be made from avariety of different metals and also potentially can be made from somecomposite materials that are capable of maintaining a very flat frontsurface for supporting the glass. Thermal expansion is important tomaintaining flatness under the widely varying temperatures often seen invehicle passenger compartments. In particular, plate frame materialshaving a thermal expansion close to the thermal expansion of glass haveless tendency to create bowing and localized surface distortions, sincethere are less stresses developed due to dissimilar thermal expansions.For example, it has been found that steel will work well for plate frame21, since glass has a thermal expansion of about 4.5×10⁻⁶ in/in/oF (8.0mm/mm/oK), while steel has a thermal expansion of about 6.5×10⁻⁶in/in/oF (11.5.0 mm/mm/oK). Alternatively, magnesium has a thermalexpansion of about 13.8×10⁻⁶ in/in/oF (24.5 mm/mm/oK), while aluminumhas a thermal expansion of about 13.0×10⁻⁶ in/in/oF (23.9 mm/mm/oK), andABS/PC plastic has a thermal expansion of about 40×10⁻⁶ in/in/oF (71mm/mm/oK), Nonetheless, it is noted that each of these materials can beused in combination with the present inventive concepts to produce amirror having beneficial aspects where the plate frame design ismodified to accommodate the dissimilar thermal expansion.

A brief discussion follows that is sufficient to provide anunderstanding of the present invention to persons skilled in this art.Nonetheless, it is noted that electrochromic mirror subassemblies, suchas EC subassembly 22, are generally well known in the art. Thus, adetailed description is not necessary to provide an understanding of thepresent invention to a person skilled in this art. Further, though aparticular EC mirror subassembly is shown, it is specificallycontemplated that the present inventive concepts will work on many suchEC mirror subassemblies.

Briefly, the illustrated EC subassembly 22 (FIG. 5) includes front andrear glass elements 35 and 36, with a layer of electrochromic (EC)material 37 between. Top and bottom electrical conductors 35′ and 36′(FIG. 6) are connected to opposing sides of the EC material 37 and areoperably connected to a control circuit 41 on a circuit board 40,described below.

The reflective layer 38 is located either on the front surface of therear glass element 36 (called a third surface reflector) or on the rearsurface of the rear glass element 36 (called a fourth surfacereflector). In the present arrangement, there is a double-sided tape 39adhering a rear of the EC mirror subassembly 22 to the front surface 23of plate frame 21. It is contemplated that other attachment means couldbe used instead of adhesive tape, such as a layer of adhesive.Alternatively, mechanical edge connectors (such as tabs or resilientfingers) near edges of the plate frame 21 could be used to retain the ECsubassembly 22 to the plate frame 21 in a multi-layer arrangementpermitting some lateral slippage of the EC subassembly 22 on the plateframe 21. It is contemplated that the EC subassembly 22 could also beretained to the plate frame 21 by the bezel 27. Alternatively, it isconceived that the reflective layer 38 can be formed directly on a frontsurface of the internal plate frame 21 as a third surface reflector, andthe second glass element 36 eliminated.

The illustrated plate frame 21 is preferably made from a stiff, strongmaterial (such as steel or magnesium) having a high strength-to-weightratio, is dimensionally very stable, and further has properties allowingit to be made with a very uniform and consistently flat surface. Themagnesium material has a thermal expansion rate of about 13.8×10⁻⁶in/in/oF (24.5 mm/mm/oK), which, based on testing, is similar enough tothe thermal expansion of glass to provide a stable arrangementsatisfactory for many automotive applications. However, it is noted thatother metals, such as steel, has thermal expansion properties closer toglass. In particular, steel has a thermal expansion of about 6.5×10⁻⁶in/in/oF (11.5.0 mm/mm/oK), which is relatively close to the thermalexpansion of about 4.5×10⁻⁶ in/in/oF (8.0 mm/mm/oK) for glass.

Where the thermal expansion of such materials is not as well matched toglass, care must be used in attaching the EC subassembly 21 to the plateframe to minimize stress during assembly and to avoid unacceptabledistortions and non-uniform stress in the glass elements 35 and 36,since such distortions can result in buckling or cracking of the glassand/or distortion of reflected images. The fluidity and tackiness of theadhesive tape 39 can also be important in reducing or distributingstress, including stress from thermal expansion or contraction. Also,the thickness of the glass elements is important in preventingdistortion of reflected images. For example, by using magnesium orsteel, it has been found that a thickness of the rear glass element 36can be reduced from the more normal glass thickness of about 2.2+mm, toa reduced glass thickness as low as about 1.6 mm, and potentially evenas low as 1.1 mm, and the front glass element 35 can be reduced inthickness to about 1.6 mm or even lower, depending upon functionalconsiderations of the mirror design. When aluminum is used, it isconceived that the thickness of plate frame 21 itself can be reduced toa surprisingly thin dimension, such as about 1.0 to 1.5 mm thick. Whendie-cast grade magnesium is used, it is conceived that the thickness ofplate frame 21 can be reduced even more, such as to about 1.0 mm orless. Also, apertures can be cut into the plate frame to further reduceweight, with the apertures having a size sufficiently small enough toallow the glass elements of the mirror subassembly to span the apertureswithout distortion.

The electrical components 24 (FIG. 6) are mounted on a circuit board(s)40 and are interconnected to each other to form an electrical circuit 41operably connected to the EC material 37 for darkening the EC material37 to reduce a reflection of glaring headlights of vehicles followingthe vehicle of mirror assembly 20. The electrical control circuit 41includes wires 42 that connect to a vehicle wiring harness that extendsfrom the mount 33 up and along the vehicle roof and down the vehicle's“A” pillar to the vehicle's electrical system.

The plate frame 21 (FIG. 6) (also called an internal, integrated frame)is made of metal such as magnesium, which is particularly strong anddimensionally accurate. The plate frame 21 is sufficiently strong to bethe primary support for mirror 20. The EC mirror subassembly 22 isattached to a front surface of the plate frame by a double-sidedadhesive tape 39 (FIG. 5). A compass and temperature display 43 can beadded, which fits into an aperture/pocket 44 in a face of the plateframe 21. The illustrated pocket 44 extends completely through the plateframe 21, but it is contemplated that it could instead be a recess thatextends only partially into the plate frame 21. Circuit boards 40include edges or tabs that are frictionally attached or that are heatstaked onto the rear surface of the plate frame 21, and carry componentssuch as diodes, lights, displays, switches, and other components 24.Alternatively, components such as diodes, lights, LEDs, displays,displays, switches, and the like can also be mounted directly on theplate frame 21, either on the front or rear surfaces 23 and 25, or inrecesses or apertures in the front or rear of the plate frame 21.Advantageously, the plate frame 21 is thermally conductive, and acts asa very good heat sink for power-using components of the EC controlcircuit 41 and for heat generating components such as diodes, lightsources, LED and the like. Also, the plate frame 21 is an excellentshield against electromagnetic interference (EMI) and radio frequencyinterference (RFI). Thus, the plate frame 21 acts as an excellent shieldwhere wire management channels and apertures are provided and the wiresare well managed tightly against a rear surface of the mirrorsubassembly, or where tabs are formed to partially encase the component.(See FIGS. 7-10.)

Since the plate frame 21 is the main structural member that carries aload of the mirror 20, the cover 26 is merely an aesthetic enclosurehung on the plate frame 21. Accordingly, the cover 26 no longer requiresthe ribs and thickness required of traditional mirror housings,especially around the mounting area near the ball-and-socket connection30. Instead, the cover 26 can thus be nothing more than a cover. Thishas great advantages, since the cover 26 can be made thinner, lighter,and from less expensive plastic. Further, molding of the cover 26 issimplified and quality improved over prior housings, since thestiffening ribs and webs around the socket area are eliminated. (Inprior art, the stiffening ribs and webs were a quality problem, sincethey tend to cause molding problems including sinks and visible marks onan outside of the housing. Further, the ribs and webs made the moldtooling much more expensive and difficult to maintain.)

Bezel 27 (FIG. 5) extends around a perimeter of the EC mirrorsubassembly 22, and has a J-shaped cross section. The J-shaped crosssection includes a straight side section 50 spaced from an edge of theglass elements 35 and 36, and a front arching section 51 with an endthat curls around and engages the front surface of the front glasselement 35 slightly inboard of an edge of the glass element 35. The sidesection 50 includes a configured trailing end with a notch 52 shaped toengage a tip 54 of the plate frame 21, and a tapered end 53.

The outer perimeter edge of the plate frame 21 includes the tip 54 thatengages notch 52, and further includes a rearward-extending perimeterlip 55 forming a recess on a rear side of the plate frame 21 forreceiving the circuit board 40. Bosses 55′ and/or stand-offs and/or tabsare located on a rear of the plate frame 21 for attachment of items tothe plate frame 21. For example, the bosses 55′ receive screws tosecurely attach the attachment component 34 to the plate frame 21. Theplate frame 21 still further includes a rearward extending attachmentflange 56. The cover 26 includes an outboard flange 57 that overlaps thetapered end 53 of the bezel 27. The illustrated outboard flange 57 ofthe cover 26 is spaced from and does not engage or press on the bezelside section 50 (and notch 52). Instead, there is a gap formedtherebetween so that there is no risk of squeaking or rattling. However,it is contemplated that the overlap could be constructed so that theoutboard flange 57 presses on the bezel side section 50 to maintainengagement of the tip 54 of the plate frame 21 with the notch 52. Theoutboard flange 57 on the cover 26 includes an inwardly extendingprotrusion 58 that engages an aperture 59 on the attachment flange 56 ofthe plate frame 21. A second attachment flange 60 on the cover 26, whichlies parallel and inboard of the flange 56, engages an inside surface ofthe attachment flange 56 and helps keep the protrusion 58 in secureattachment with the aperture 59.

The cover 26 includes a relatively thin rear wall 26′ of uniformthickness, with minimal reinforcement ribs and webs, since they are notneeded for structure. A perimeter wall 26′ (FIG. 6) extends forwardlyfrom the rear wall 26′ to define a concave shape. A top portion of theperimeter wall 26′ includes a forwardly open slot 62 for receiving theball-and-socket connection 30.

There are a variety of different mounts that can be used to hold thepresent mirror 20, including single and double ball-and-socket mounts.The illustrated mount 33 (FIG. 6) includes an injection-molded ordie-cast base 65 adapted for connection to a window-adhered bracket 66via a clip 67 on the base 65. The clip 67 engages opposing sides of thebracket 66. A tunnel cover 68 telescopingly attaches to a top flange 69of the base 65 for covering wires 42 extending from the mirror 20 upthrough attachment component 34 and base 65 to a location above avehicle headliner. The base 65 includes reinforcement ribs and webs tosecure a down stem 70, which stem 70 supports the ball section 31. Awireway is formed through the ball section 31 and stem 70 for routingwires from the mirror 20 (or, alternatively, the wires can be routedparallel and above the stem 70 in a semi-hidden position).

The attachment component 34 (FIG. 6) includes a crown section 72 and anattachment section 73. The attachment section 73 includes atriangularly-shaped flat side 74 shaped for stably engaging a rearsurface of the plate frame 21. Three apertured bosses 75 on theattachment section 73 align with three apertured bosses 76 in the plateframe 21, for receiving screws 77 to secure the plate frame 21 to theattachment section 73. The attachment section 73 is generally hollow tofacilitate molding, but includes one or more reinforcement ribs 78 thatstiffen and strengthen the attachment section 73. The illustratedcomponent 34 includes a wireway passage that extends laterally throughthe attachment component 34 and upwardly through a center of the crownsection 72. The crown section 72 includes a plurality of resilientprotrusions 79 that extend upwardly, and that have outer surfacesforming a cylinder for receiving a hoop clamp 80, and that have innersurfaces forming a socket 32 for receiving the ball section 31. As theball section 31 is extended downwardly into the socket 32, theprotrusions 79 flex outward and then return to their inward positions.Thereafter, the clamp 80 is applied, holding the protrusions 79 snuglyagainst the ball section 31 for adequate static friction to hold aselected position, but with sufficient controlled force to permitangular adjustment. It is noted that the ball section 31 and stem 70could be designed to extend rearwardly, instead of downwardly.

It is noted that the bezel 27 (FIG. 6) includes a rearwardly extendingtab 82 that closes a front portion of the slot 62 in a top of the cover26.

Mirror 20′ (FIG. 2A) is similar to mirror 20 (FIG. 2), except thatmirror subassembly 20′ includes a back cover 26′ 30% thinner in depth.(The front profile of the mirror subassembly 20′ and its internalcomponents are basically the same as mirror 20.) Also, the mount 33′ ofthe apparatus 18′ has a different shape.

The mirrors shown in FIGS. 7-29 are similar to but are modified from themirror 20. Features and characteristics on the mirrors that areidentical or similar to mirror 20 are identified using identical numbersalong with the letters “A”, “B”, etc., respectively, to reduce redundantdiscussion.

In the illustrated mirror 20, the socket 32 is formed by an attachmentcomponent 34 that is attached directly to the plate frame 21, and thesocket 32 is formed on a mount 33. In a second embodiment of FIGS. 7-8,the plate frame 21A of a mirror 20A includes a ball section 31A and stem70A formed integrally from the material of the plate frame 21A (FIGS.7-9). The ball section 31A and stem 70A extend rearward from the plateframe 21. It is noted that several different materials may be used toform the plate frame 21A with integral ball section 31A and stem 70A,such as magnesium, aluminum, and deep draw steels and even potentially astrong, stiff plastic or composite.

The mirror 20A (FIGS. 7-8) includes a plate frame 21A attached to amount 33A. The illustrated plate frame 21A is a die-cast magnesium part,with an integrally formed stem 70A and ball section 31A integrally castonto a back side of the plate portion 89A of the plate frame 21A. Themount 33A includes a tube 90A with a formed end 91A holdingsocket-forming bearings 32A against the ball section 31A. A coil spring92A biases the bearings 32A against the end 91A. It is contemplated thatmount 33A can be a one-ball mount, with the ball-and-socket connection30A being only at a single end, or can be a two-ball mount, with aball-and-socket connection at each end. The illustrated stem 70A andball section 31A have a wireway/passageway 94A formed therethrough forpassing wires 42A from the mirror 20A to the mount 33A. A lateralopening 95A is formed at a root of the stem 70A, slightly above theplate portion 89A of the plate frame 21A. The opening permits wires 42Ato be passed out a side of the stem 70A to locations optimally suitedfor attachment to electrical components 24 and circuit 41. It iscontemplated that the passageway 94A can be a hole requiringfeed-through of wires 42A, or can be an open channel with an overhangingside flange permitting lay-in of wires 42A (with the overhanging flangeboth helping to contain the wires and also shield any EMI or RFIemissions).

Mirror 20B (FIG. 9) includes a plate frame 21B made from a sheet of adeep-draw steel. The stem 70B and ball section 31B are formed from thematerial of the plate portion 89B of the plate frame 21B. A shieldingtunnel or channel 97B is formed on a face of the plate portion 89B formanaging wires 42B as the wires 42B pass from the passageway 94B alongthe channel 97B and through the aperture 44B. The channel 97B can beformed under the second mirror element 36, with the mirror element 36bridging over the channel 97B. Alternatively, the channel 97B can beformed in a chin area of the mirror 20B, below the EC mirror subassembly22B, where the electrical connector or device 98B does not interferewith the glass elements of the EC mirror subassembly 22B. For example,the device 98B could be a button on the “chin” area of a mirror assembly20B. Alternatively, a channel (not unlike channel 97B) can be formed ona side of the plate portion 89B for communicating wires 42B along a sideof the plate portion 89B. Notably, the channel 97B is large enough tocarry the wires 42B without a tight fit, but the access opening to thechannel 97B is sufficiently small such that the elements 36 of the ECmirror subassembly 22B can span the access opening without distortion asthey bridge the access opening.

Mirror 20C (FIG. 10) includes a plate frame 21C and a circuit board 40C,with buttons 100C and switches 101C operably mounted directly onto andinto the plate frame 21C and the circuit board 40C. FIG. 10 is avertical cross section taken through a lower central “chin” area on themirror 20C. The vertical cross section passes through the button 100Cand shows each of the plate frame 21C, the circuit board 40C, the bezel27C, the button 100C, and the components of the switch 10C. The lowerportion 89C′ of the plate portion 89C of the plate frame 21C includes anaperture 102C for receiving the button 100C, and further includes aforward rib 103C. The rib 103C includes a tip that forms a toppivot/guide for the button 100C and further includes a bottom tip thatforms a stop that engages the button 100C for limiting the maximum depthof movement of the button 100C when the button 100C is depressed. Therib 103C also promotes a better and more consistent gap and appearancearound the button 100C. Alternatively, it is contemplated that the rib103C and lower portion 89C′ can be components separate from the plateframe 21C. In such case, they would be attached to and supported on thecircuit board 40C or attached to and supported on the bezel 27C.

Two electrical contacts 105C and 106C are positioned on the circuitboard 40C and connected to the electrical control circuit 41C on thecircuit board 40C. A patch of resilient film 107C is positioned over theelectrical contacts 105C and 106C, and an electrically conductive member108C is attached under the patch 107C in a position where it willelectrically connect the contacts 105C and 106C when the switch 101C ismade. The button 100C is positioned over the patch of film 107C. Whenthe button 100C is depressed, the button 100C depresses film 107C andmoves the conductive member 108C into operative contact with thecontacts 105C and 106C, completing the circuit for operating whateverelectrical device is connected to the electrical contacts 105C and 106C.When the button 100C is released, the resilient patch of film 107Cbiasingly moves the button 100C back to an at-rest position, where theconductive member 108C disconnects from the contacts 105C and 106C andbreaks the circuit.

Though mirrors 20-20C are flat mirrors, it is contemplated that thepresent arrangement could be used in non-flat mirrors and asphericmirrors. Such mirrors are often used in Europe. Such mirrors have glasselements that are bent or dished. Thus, reflected images seen in themirror are reduced in size, but a larger viewing area is visible.

In the embodiment of FIG. 11, a mirror 20D includes an internal plateframe 21D having a tubular section 109D integrally formed thereon thatextends rearwardly. The tubular section 109D includes longitudinallyextending grooves 110D, three such grooves being illustrated. Acrown-shaped bearing 72D defines a socket 32D for receiving a ballsection 31D. An annular spring 11D extends around the tube section 109Dand includes inwardly extending sections 112D (FIG. 12) that extend intothe grooves 110D in the tube section and into grooves 113D in the crownbearing 72D, to retain the crown bearing 72D in place. Thus, the ballsection 31D engages the socket 32D in the crown bearing 72D to form anangularly adjustable ball and socket connection. A hole 94D extendsthrough the stem 70D and through the ball section 31D to allow wirepassage.

In the mirror arrangement 20E (FIG. 13), the plate frame 21E includes atube section 109E similar to tube section 109D (FIG. 11). However, anend of the tube section 109E includes an annular ridge or a plurality ofprotrusions or detents 115E that extends outwardly. The crown 72Eincludes an inner portion 116E that forms the socket 32E. A spring 111Ewraps around the crown and biases the inner sections 116E inwardlyagainst the ball section 31E. An annular trailing flange 117E on thecrown 72E extends from the inner portion 116E around the end of the tubesection 109E. The annular reversed flange 117E includes a recess thatmateably snap-lockingly engages the detent 115E to retain the crownbearing 72E in position. The stem sections 70E extend from the ballsection 31E and integrally connects to a mount for attachment to avehicle windshield.

Mirror 20F (FIGS. 14-19) discloses a complete mirror having aconstruction similar to mirror 20A and 20B. In particular, we note theplate frame 21F that incorporates an elongated tunnel 97F forming ashield for wires 42F. Notably, the shield 97F further includes anenlarged tab 97F′ that partially shields a circuit board 98F. Also, thebutton 100F (FIG. 19) includes a switch 101F mounted on a circuit board98F and that is operable by button 100F under the mirror subassembly 22Fand through a hole 21F′ in the integrated plate frame 21F. A bezel 50Fextends around the arrangement and includes a lip 50F′ that snappinglyengages an end 54F of the plate frame 21F to retain the bezel inposition. The back cover 26F also includes a front edge 26F′ thatengages the edge of the plate frame 21F to retain the back cover inposition, such as by a similar snap-attach connection.

Mirror 20G (FIGS. 20-23) includes a mirror arrangement similar to theintegrally formed ball section and stem of the plate frame 21A of mirror20A (FIG. 7), however, the ball section 31G and stem 70G are formed froma deep-draw material that is flowed and formed into the tube section 70Gand ball section 31G to have a constant thin wall. Also, the tunnelshield 97G (FIG. 22) is formed on a backside of the plate frame 21G andfurther an aperture or hole 95G is formed in a base or root of the stem70G for egress and entrance of wiring. Still further, a buttonarrangement 100G (FIG. 23) is formed along a lower central edge of themirror in a chin area similar to mirror 20G (FIG. 23). The illustratedbutton 100G is operably supported on the bezel 27G, and the switch 10Gis supported on the circuit board 40G.

The mirror 20H (FIGS. 24-29) includes a plate frame 21H (FIG. 26), anelectrochromic mirror subassembly 22H supported on the plate frame 21H,and a bezel 27H and back cover 26H. The plate frame 21H includes acup-shaped mount 120H including a flat wall 121H formed from thematerial of plate portion 89H of plate frame 21H. A connection member122H includes a flat base 1231H that engage wall 121H, a stem 124H, anda ball section 31H. A washer 125H is positioned under the flat section121H with the base 123H opposite the washer 125H. A screw 126H includesa head 127H positioned within the cup-shaped member 121H, and includes athreaded shaft 127H′ that extends through a hole in the washer 125H,through a hole in the flat wall 121H, and threadably into a hole thatextends up through stem 124H into ball section 31H. The screw 126Hincludes a length that extends substantially into the ball section 311H.However, it is contemplated that the shaft length of the screw 126H canbe significantly shorter. Further, the hole can be extended through theball section 31H and connected to a passageway formed laterally out of aside of the stem 124H. Thus, a wire passageway can be formed tocommunicate wires centrally through the ball section 311H into the stem124H and out a side of the stem under the cover 26H into a backside ofthe plate frame 211H for connection to circuitry within the mirror.

It is contemplated that the present inventive concepts can be used incombination with mirrors (interior and/or exterior) having manydifferent options to create synergistic and non-obvious combinationsthat provide surprising and unexpected benefits not previously possible.For example, turning now to FIG. 30, an interior mirror assembly 502includes a bezel 555 and a case 556 mounted on an internal frame 621(FIG. 31). The bezel and the case combine to define a mirror housing forincorporation of features in addition to a reflective element andinformation display. Commonly assigned U.S. Pat. No. 6,102,546; U.S. DPat. No. 410,607; U.S. Pat. Nos. 6,407,468; 6,420,800; and 6,471,362,the disclosures of which are incorporated in their entireties herein byreference, describe various bezels, cases, and associated buttonconstruction for use with the present invention.

As depicted in FIG. 30, the mirror assembly may include top and/orbottom microphones 559. Examples of microphones for use with the presentinvention are described in commonly assigned U.S. patent applicationSer. Nos. 09/144,176 and 10/076,158, the disclosures of which areincorporated in their entireties herein by reference. As depicted inFIGS. 30-32, the microphone 561 or microphones 560 may be mounted on thetop of the mirror assembly, on the bottom of the mirror assembly, on thebackside of the mirror case, or anywhere within the mirror case orbezel. Preferably, two microphones are incorporated, one near each end,into the mirror assembly on the backside of the mirror case within therecessed portion as shown in FIGS. 30-32. These systems may beintegrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays.

With further reference to FIG. 30, mirror assembly 502 includes firstand second illumination assemblies 567, 571. Various illuminationassemblies and illuminators for use with the present invention aredescribed in commonly assigned U.S. Pat. Nos. 5,803,579; 6,335,548; and6,521,916, the disclosures of which are incorporated in their entiretiesherein by reference. As further depicted in FIG. 32, each illuminationassembly preferably comprises a reflector, a lens, and an illuminator(not shown). Most preferably, there are two illumination assemblies,with one generally positioned to illuminate a driver seat area. Theremay be only one or may be additional illuminator assemblies, such as oneto illuminate a center console area, overhead console area or an areabetween the front seats.

With further reference to FIG. 30, mirror assembly 502 includes firstand second switches 575, 577. Suitable switches for use with the presentinvention are described in detail in commonly assigned U.S. Pat. Nos.6,407,468; 6,420,800; 6,471,362; and 6,614,579, the disclosures of whichare incorporated in their entireties herein by reference. These switchesmay be incorporated to control the illumination assemblies, thedisplays, the mirror reflectivity, a voice-activated system, a compasssystem, a telephone system, a highway toll booth interface, a telemetrysystem, a headlight controller, a rain sensor, etc. Any other display orsystem described herein or within the references incorporated byreference may be incorporated in any location within the associatedvehicle and may be controlled using the switches.

With further reference to FIG. 30, mirror assembly 502 includesindicators 583. Various indicators for use with the present inventionare described in commonly assigned U.S. Pat. Nos. 5,803,579; 6,335,548;and 6,521,916, the disclosures of which are incorporated in theirentireties herein by reference. These indicators may indicate the statusof the displays, the mirror reflectivity, a voice-activated system, acompass system, a telephone system, a highway toll booth interface, atelemetry system, a headlight controller, a rain sensor, etc. Any otherdisplay or system described herein or within the references incorporatedby reference may be incorporated in any location within the associatedvehicle and may have a status depicted by the indicators.

With further reference to FIG. 30, mirror assembly 502 includes firstand second light sensors 586, 588 (glare and ambient sensors in FIG. 7).Preferred light sensors for use within the present invention aredescribed in detail in commonly assigned U.S. Pat. Nos. 5,923,027 and6,313,457, the disclosures of which are incorporated in their entiretiesherein by reference. The glare sensor and/or ambient sensorautomatically control the reflectivity of a self-dimming reflectiveelement as well as the intensity of information displays and/orbacklighting. The glare sensor is used to sense headlights of trailingvehicles and the ambient sensor is used to detect the ambient lightingconditions that the system is operating within. In another embodiment, asky sensor may be incorporated positioned to detect light levelsgenerally above and in front of an associated vehicle, the sky sensormay be used to automatically control the reflectivity of a self-dimmingelement, the exterior lights of a controlled vehicle and/or theintensity of information displays.

With further reference to FIG. 30, mirror assembly 502 includes first,second, third, and fourth operator interfaces 590, 591, 592, 593 locatedin mirror bezel 555. Each operator interface is shown to comprise abacklit information display “A”, “AB”, “A1”, and “12”. It should beunderstood that these operator interfaces can be incorporated anywherein the associated vehicle, for example, in the mirror case, accessorymodule, instrument panel, overhead console, dashboard, seats, centerconsole, etc. Suitable switch construction is described in detail incommonly assigned U.S. Pat. Nos. 6,407,468; 6,420,800; 6,471,362; and6,614,579, the disclosures of which are incorporated in their entiretiesherein by reference. These operator interfaces may control theillumination assemblies, the displays, the mirror reflectivity, avoice-activated system, a compass system, a telephone system, a highwaytoll booth interface, a telemetry system, a headlight controller, a rainsensor, etc. Any other display or system described herein or within thereferences incorporated by reference may be incorporated in any locationwithin the associated vehicle and may be controlled using an operatorinterface or interfaces. For example, a user may program a display ordisplays to depict predetermined information or may program a display ordisplays to scroll through a series of information, or may enter setpoints associated with certain operating equipment with associatedsensor inputs to display certain information upon the occurrence of agiven event. In one embodiment, for example, a given display may be in anon-illuminated state until the engine temperature is above a threshold,the display then automatically is set to display the engine temperature.Another example is that proximity sensors located on the rear of avehicle may be connected to a controller and combined with a display ina rearview mirror to indicate to a driver the distance to an object; thedisplay may be configured as a bar that has a length proportional to thegiven distance.

Although specific locations and numbers of these additional features aredepicted in FIG. 30, it should be understood that fewer or moreindividual devices may be incorporated in any location within theassociated vehicle and as described within the references incorporatedherein.

Turning now to FIG. 31, there is shown a section view of a mirrorassembly 602, with a reflective electrochromic subassembly 605 adheredto an internal plate frame 621 with double-sided adhesive foam tape 622.Attachment component 634 is screwed to (or integrally formed from) plateframe 621 and defines a crown 672 that engages a ball section 624. Thedepicted section of FIG. 31 is taken along cut line 6-6 of FIG. 30,shows a preferred positional relationship of third and fourthinformation displays 626, 641 with respect to reflective EC element 605along with third information display backlighting 627 within a housingdefined by case 656 and bezel 655. Mirror assembly 602 is also shown tocomprise a microphone 659; first operator interface 690; along withcircuit board 695; mirror mount 657 and accessory module 658. The mirrormount 657 and/or an accessory module 658 may comprise compass sensors, acamera, a headlight control, an additional microprocessor, a rainsensor, additional information displays, additional operator interfaces,etc.

Turning now to FIG. 32, there is shown an exploded view of a mirrorassembly 702. FIG. 32 provides additional detail with regard to onepreferred positional relationship of individual components, as well asproviding additional structural detail of a mirror assembly. Mirrorassembly 702 comprises a reflective element 705 within a bezel 755 and amirror case 756. A mirror mount 757 is included for mounting the mirrorassembly within a vehicle. It is noted that a person skilled in the artof vehicle mirror design can re-design the bezel 755, mirror case 756,and tube mount 757 to be replaced with other bezel designs and/or mirrorhousing designs previously described in this application. It should beunderstood that a host of accessories may be incorporated into the mount757 and/or onto the plate frame 621 in addition to a power packadjuster, such as a rain sensor, a camera, a headlight control, anadditional microprocessor, additional information displays, compasssensors, etc. These systems may be integrated, at least in part, in acommon control with information displays and/or may share componentswith the information displays. In addition, the status of these systemsand/or the devices controlled thereby may be displayed on the associatedinformation displays.

Mirror assembly 702 is shown in FIG. 32 to further comprise thirdinformation display 726 with third information display backlighting 737,738, 739; first and second microphones 760, 761; and including otherknown options such as a first reflector with a first lens; a secondreflector with a second lens; a glare sensor; an ambient light sensor;first, second, third, and fourth operator interfaces 790, 791, 792, 793,with first, second, third, and fourth operator interface backlighting790 a, 791 a, 792 a, 793 a; a circuit board 795 having a compass sensormodule 799; and a daughter board 798 with an input/output bus interface797.

Preferably, the illumination assemblies with associated light source areconstructed in accordance with the teachings of commonly assigned U.S.Pat. Nos. 5,803,579; 6,335,548; and 6,521,916, the disclosures of whichare incorporated in their entireties herein by reference.

Preferably, the glare light sensor and the ambient light sensor areactive light sensors as described in commonly assigned U.S. Pat. Nos.6,359,274 and 6,402,328, the disclosures of which are incorporated intheir entireties herein by reference. The electrical output signal fromeither, or both, of the sensors may be used as inputs to a controller796 on the circuit board 740 or 795 to control the reflectivity ofreflective element 705 and/or the intensity of third information displaybacklighting. The details of various control circuits for use herewithare described in commonly assigned U.S. Pat. Nos. 5,956,012; 6,084,700;6,222,177; 6,224,716; 6,247,819; 6,249,369; 6,392,783; and 6,402,328,the disclosures of which are incorporated in their entireties herein byreference. These systems may be integrated, at least in part, in acommon control with information displays and/or may share componentswith the information displays. In addition, the status of these systemsand/or the devices controlled thereby may be displayed on the associatedinformation displays.

Although the compass sensor module 799 is shown to be mounted circuitboard 795 in FIG. 32, it should be understood that the sensor module maybe located within mount 757, an accessory module 758 positionedproximate mirror assembly 702 or at any location within an associatedvehicle such as under a dashboard, in an overhead console, a centerconsole, a trunk, an engine compartment, etc. Commonly assigned U.S.Pat. Nos. 6,023,229 and 6,140,933, as well as commonly assigned U.S.patent application Ser. Nos. 10/210,910 and 60/360,723 and AttorneyDocket GEN10 PP-443 entitled Electronic Compass System, the disclosuresof which are incorporated in their entireties herein by reference,describe in detail various compass systems for use with the presentinvention. These systems may be integrated, at least in part, in acommon control with information displays and/or may share componentswith the information displays. In addition, the status of these systemsand/or the devices controlled thereby may be displayed on the associatedinformation displays.

Daughter board 798 is in operational communication with circuit board795. Circuit board 795 may comprise a controller 796, such as amicroprocessor, and daughter board 798 may comprise an informationdisplay (not shown in FIG. 7). The microprocessor may, for example,receive signal(s) from the compass sensor module 799 and process thesignal(s) and transmit signal(s) to the daughter board to control adisplay to indicate the corresponding vehicle heading. As describedherein and within the references incorporated by reference herein, thecontroller may receive signal(s) from light sensor(s), rains sensor(s)(not shown), automatic vehicle exterior light controller(s) (not shown),microphone(s), global positioning systems (not shown), telecommunicationsystems (not shown), operator interface(s), and a host of other devices,and control the information display(s) to provide appropriate visualindications.

Controller 796 (or controllers) may, at least in part, control themirror reflectivity, exterior lights, rain sensor, compass, informationdisplays, windshield wipers, heater, defroster, defogger, airconditioning, telemetry systems, voice recognition systems such asdigital signal processor-based voice-actuation systems, and vehiclespeed. The controller 796 (or controllers) may receive signals fromswitches and/or sensors associated with any of the devices describedherein and in the references incorporated by reference herein toautomatically manipulate any other device described herein or describedin the references included by reference. The controller 796 may be, atleast in part, located outside the mirror assembly or may comprise asecond controller elsewhere in the vehicle or additional controllersthroughout the vehicle. The individual processors may be configured tocommunicate serially, in parallel, via Bluetooth protocol, wirelesscommunication, over the vehicle bus, over a CAN bus or any othersuitable communication.

Exterior light control systems as described in commonly assigned U.S.Pat. Nos. 5,990,469; 6,008,486; 6,130,421; 6,130,448; 6,255,639;6,049,171; 5,837,994; 6,403,942; 6,281,632; 6,291,812; 6,469,739;6,465,963; 6,587,573; 6,429,594; 6,379,013; and 6,774,988 and U.S.patent application Ser. Nos. 09/538,389; 09/678,856; 09/847,197;60/404,879; and 10/235,476, the disclosures of which are incorporated intheir entireties herein by reference, may be incorporated in accordancewith the present invention. These systems may be integrated, at least inpart, in a common control with information displays and/or may sharecomponents with the information displays. In addition, the status ofthese systems and/or the devices controlled thereby may be displayed onthe associated information displays.

Moisture sensors and windshield fog detector systems are described incommonly assigned U.S. Pat. Nos. 5,923,027 and 6,313,457, thedisclosures of which are incorporated in their entireties herein byreference. These systems may be integrated, at least in part, in acommon control with information displays and/or may share componentswith the information displays. In addition, the status of these systemsand/or the devices controlled thereby may be displayed on the associatedinformation displays.

Commonly assigned U.S. Pat. No. 6,262,831, the disclosure of which isincorporated herein by reference in its entirety, describes powersupplies for use with the present invention. These systems may beintegrated, at least in part, in a common control with informationdisplays and/or may share components with the information displays. Inaddition, the status of these systems and/or the devices controlledthereby may be displayed on the associated information displays.

It is contemplated that the present invention would be useful in insideor outside rearview mirrors having optical electrochromic mirrorelements, convex mirror elements, aspheric mirror elements, planarmirror elements, non-planar mirror elements, hydrophilic mirrorelements, hydrophobic mirror elements, and mirror elements having thirdsurface and fourth surface reflectors. It is further contemplated thatthe present invention will be useful on mirrors that are transflective,or that have a third or fourth surface mirror element with patterns oflines thereon to optimize the effect of visible light (sometimes called“jail bars”). Further, the present invention is useful with mirrorshaving first surface or fourth surface heaters, anti-scratch layers, andcircuit boards including flexible circuit boards, and circuit board andheater combinations, such as heaters having embedded or integratednon-heater functions such as signal ellipses and signal diffusants,locating holes or windows for light pass-through. The present inventionis also useful with potted or snap-attached or elastomeric bezels, anduseful with carriers having an ultra-flat front surface. Also,additional options can be integrated into the mirrors including signallighting, key lights, radar distance detectors, puddle lights,information displays, light sensors and indicator and warning lighting,retainers with living hinges, and integrated housings for receiving andsupporting said components. Still further, it is conceived that thepresent mirror can include a manually folding or power folding mirrors,extendable mirrors, and mirrors with a wide field of view, and withinformation on the mirror such as “object in mirror is closer than mayappear” or other indicia, such as “heated” or “auto-dim”. Still further,the present invention is useful with a blue glass mirror or “bluechemical” darkening mirror. Still further, efficiencies can be had byincorporating the present concepts with mirrors having an electrochromicmirror subassembly with front and rear glass mirror elements with edgeshaving a “zero offset” (i.e. less than about 1-mm difference betweenperfect alignment edges of the mirror elements), an edge seal, includingclear reflective or opaque edge seals, and/or second surface chrome or achrome bezel.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

1. A rearview mirror apparatus for vehicles comprising: a mirrorincluding an internal frame having a front surface, and anelectrochromic mirror subassembly supported on the front surface; amount adapted to support the mirror in a vehicle; and anangularly-adjustable connector adjustably supporting the mirror on themount, the angularly-adjustable connector including a ball section and asocket-defining section, with the ball section being formed on one ofthe internal frame and the mount, and the socket-defining section beingformed on the other of the internal frame and the mount; thesocket-defining section receiving and supporting the ball section forangular adjustment, but engaging the ball section with sufficient forceand friction to hold the mirror in a selected angular position once themirror is released by a vehicle driver.
 2. The apparatus defined inclaim 1, wherein the socket-defining section includes a casing connectedto a plate frame and a bearing positioned within the casing.
 3. Theapparatus defined in claim 2, wherein the casing is formed of materialthat is contiguous and continuous with material of the plate frame. 4.The apparatus defined in claim 3, wherein the plate frame material isdeep-draw material, and the casing is a tubular section deep-drawn fromthe material of the plate frame.
 5. A rearview mirror for vehiclescomprising: an internal metal plate; an electrochromic mirrorsubassembly supported in front of the plate; and an electrical circuitsupported by the metal plate and operably connected to theelectrochromic mirror subassembly, the metal plate having heatconduction properties and acting as a heat sink for the circuit.
 6. Arearview mirror for vehicles comprising: an internal metal plate; anelectrochromic mirror subassembly supported in front of the plate; andan electrical circuit supported by the metal plate and operablyconnected to the electrochromic mirror subassembly, the electricalcircuit including electrical devices that generate at least one of EMIemissions and RFI emissions, and the metal plate having anintegrally-formed section shaped to at least partially cover and shieldthe electrical device to reduce EMI and RFI emissions.
 7. A rearviewmirror for vehicles comprising: a mirror subassembly; a frame supportingthe mirror subassembly; a cover attached to the frame and covering aback and edges of the mirror subassembly; and the mirror subassemblyforming a front surface and the cover forming a rear surface of themirror, the front and rear surfaces including areas defining a pluralityof different depth dimensions, with at least 50% of the depth dimensionsbeing less than about 3 centimeters.
 8. The rearview mirror defined inclaim 7, wherein each end section is 25% of total width, and each endsection is less than 3-cm depth.
 9. The rearview mirror defined in claim7, wherein at least 50% of the depth dimensions are less than about 2centimeters.
 10. A rearview mirror for vehicles comprising: an internalplate; a back cover supported by the plate and covering a rear of theplate; an electrochromic mirror element supported in front of the plate;at least one button operably supported by the plate; and an electricalcircuit supported by the plate and operably connected to the button forcontrolling an electrical feature of the vehicle.
 11. A plate frameadapted for use in a rearview mirror for vehicles comprising: aninternal plate frame including a smooth front surface adapted forsupporting a rearview mirror element; and an integrally-formedprotrusion extending rearwardly from the plate, the protrusion includinga stem and a ball section on an end of the stem that is adapted to forma ball-and-socket connection for angularly and adjustably supporting theinternal plate and mirror elements attached to and supported by theinternal plate.
 12. A mirror comprising the frame defined in claim 11,and including an electrochromic mirror subassembly attached to thesmooth front surface and further including a mount having a socketoperably engaging the ball section for angular adjustment.
 13. A plateframe adapted for use in a rearview mirror for vehicles comprising: aninternal plate frame including a smooth front surface adapted forsupporting a rearview mirror element; an integrally-formed tubularsection extending rearwardly from the plate; and bearings forming asocket in an end of the tubular section, the bearings being adapted toreceive a ball section to form a ball-and-socket connection forangularly and adjustably supporting the internal plate frame and therearview mirror element on a mirror mount having the ball section.
 14. Arearview mirror for vehicles comprising: an internal plate frame havinga smooth front surface; a reflector layer on the front surface; anelectrochromic material covering the reflector layer; and a glasselement on the electrochromic material that contains the electrochromicmaterial on the reflector layer against the front surface.
 15. Themirror defined in claim 14, including an electrical circuit supported bythe plate frame and operably connected to the electrochromic materialfor controlling the electrochromic material of the vehicle.